Building Our Own Welding Fixtures
At William Hughes, the design and manufacture of custom welding fixtures—or custom jigs— are a critical step in the production of complex wire assemblies and our more complicated 3D wire forms.
These fixtures ensure that each component within a welded structure is accurately aligned and consistently held in position during the welding process. Without them, repeatability and dimensional conformity would be difficult to achieve, particularly when working with intricate 3D geometries common in automotive, aerospace, and electric vehicle (EV) manufacturing.
What Is a Welding Fixture and Why Is It Essential?
A welding fixture, sometimes referred to as a welding jig, is a precisely engineered tool that supports, locates, and holds multiple components in place during welding. For wire form assemblies, this tool ensures that all wires are correctly positioned relative to each other so that joints are created with maximum structural integrity and visual consistency.
Fixtures at William Hughes are used throughout the welding process. Initially, wires are loaded into the custom jig, which holds them securely in place. Once the weld is complete, the assembly is removed and placed in a dedicated checking fixture to verify that all dimensions and weld locations meet the required tolerances. This dual-fixture system helps us maintain the tight quality standards expected by Tier 1 manufacturers and OEMs.
Depending on the welding technology required, we produce our fixtures in-house using a mixture of steel, high-density polymer and brass. Materials are selected based on design principles such as quality, tool life, ease of maintenance, heat dispersion and cost.
Designing and Manufacturing Custom Welding Jigs In-House
By designing and producing our own custom jigs, we can tailor each fixture precisely to the part geometry, production process, and volume requirements. Our engineers take into account numerous factors during jig development, including part complexity, weld sequence, thermal behaviour and operator ergonomics. This means each fixture is not only dimensionally accurate but also practical and efficient for repeated use on the shop floor.
We use a combination of materials—such as steel, high-density polymers, and brass—chosen for their balance of durability, heat resistance, and ease of maintenance. These materials allow us to design fixtures that perform well under the thermal loads and mechanical stresses typical of high-volume welding. Moreover, designing in-house gives us the agility to respond quickly to design changes and to refine fixtures iteratively during prototyping or new product introduction.
The Benefit of Jig Design for Assembly
In the context of automated or semi-automated welding systems, fixture precision becomes even more critical. Robotic welding arms depend on the consistent presentation of components, and even small misalignments can cause welds to fail inspection. By engineering jigs specifically for the end-use application, we enable smooth integration between fixture, part, and welding technology—supporting lean production methodologies and long-term manufacturing stability.
For procurement professionals seeking reliable partners in wire assembly and welding, our in-house jig capability offers several tangible benefits. It shortens lead times by eliminating dependency on third-party tooling suppliers. It also supports rapid iteration during early-stage development, especially where prototypes and pre-production runs are required at pace. Most importantly, it underpins the repeatability and quality assurance processes that are vital for regulatory compliance and customer trust.
By combining custom welding fixture design with our expertise in robotic and manual welding, we offer a vertically integrated solution that aligns with supplier evaluation criteria for many Tier 1 and OEM customers.
Common Questions About Welding Fixtures and Jig Design
What are custom welding fixtures used for in manufacturing?
They are used to hold wire or metal components in place during welding, ensuring precision and consistency in the final assembly.
Why is it important to design jigs in-house?
In-house jig design enables tighter integration with production systems, faster turnaround, and the flexibility to adapt designs quickly during prototyping or process optimisation.
What types of materials are used for jigs and fixtures?
Materials like steel, polymers, and brass are selected for their strength, heat resistance, and maintainability, depending on the fixture's role and welding environment.
How does jig design improve assembly outcomes?
Good jig design ensures accurate part placement, reduces errors, and contributes to consistent weld quality—especially in automated or high-tolerance applications.
If you’re reviewing suppliers for precision wire assemblies, welded components or jig-supported manufacturing, we’d be happy to discuss your requirements. William Hughes offers full in-house fixture design, prototyping and production services, with a proven track record in delivering complex assemblies to Tier 1 and OEM customers. Get in touch today to explore how we can support your next project.
